U.S. patent number 10,961,912 [Application Number 17/122,433] was granted by the patent office on 2021-03-30 for direct drive unit removal system and associated methods.
This patent grant is currently assigned to BJ Energy Solutions, LLC. The grantee listed for this patent is BJ Energy Solutions, LLC. Invention is credited to Joseph Foster, Ricardo Rodriguez-Ramon, Nicholas Tew, Tony Yeung.
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United States Patent |
10,961,912 |
Yeung , et al. |
March 30, 2021 |
Direct drive unit removal system and associated methods
Abstract
Described herein are embodiments of systems and methods for the
removal of a direct drive unit (DDU) housed in an enclosure, such
as a direct drive turbine (DDT) connected to a gearbox for driving
a driveshaft connected to a pump for use in a hydraulic fracturing
operations.
Inventors: |
Yeung; Tony (Tomball, TX),
Rodriguez-Ramon; Ricardo (Tomball, TX), Foster; Joseph
(Tomball, TX), Tew; Nicholas (Tomball, TX) |
Applicant: |
Name |
City |
State |
Country |
Type |
BJ Energy Solutions, LLC |
Houston |
TX |
US |
|
|
Assignee: |
BJ Energy Solutions, LLC
(Houston, TX)
|
Family
ID: |
1000005276260 |
Appl.
No.: |
17/122,433 |
Filed: |
December 15, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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15929924 |
May 29, 2020 |
10895202 |
|
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|
62899975 |
Sep 13, 2019 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F02C
7/20 (20130101); F02C 7/32 (20130101); F02C
7/36 (20130101) |
Current International
Class: |
F02C
7/20 (20060101); F02C 7/36 (20060101); F02C
7/32 (20060101) |
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Other References
AFGlobal Corporation, Durastim Hydraulic Fracturing Pump, A
Revolutionary Design for Continuous Duty Hydraulic Fracturing,
2018. cited by applicant.
|
Primary Examiner: Gartenberg; Ehud
Assistant Examiner: Olynick; David P.
Attorney, Agent or Firm: Womble Bond Dickinson (US) LLP
Parent Case Text
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. Non-Provisional
application Ser. No. 15/929,924, filed May 29, 2020, titled "DIRECT
DRIVE UNIT REMOVAL SYSTEM AND ASSOCIATED METHODS," which claims the
benefit of and priority to U.S. Provisional Application No.
62/899,975, filed Sep. 13, 2019, titled "TURBINE REMOVAL SYSTEM,"
the entire disclosures of each of which are incorporated herein by
reference.
Claims
What is claimed is:
1. A direct drive unit (DDU) removal system, the system comprising:
an enclosure housing a DDU, the DDU including a gearbox and a
turbine engine connected to the gearbox to drive a driveshaft
connected to a pump for use in high-pressure, high-power hydraulic
fracturing operations, a DDU positioner assembly positioning the
DDU housed in the enclosure and facilitating removal of the DDU
from the enclosure, the DDU positioner assembly comprising: a
plurality of longitudinal rails extending in a longitudinal
direction along a central axis of the DDU; a plurality of lateral
rails extending in a lateral direction transverse to the
longitudinal direction and mounted to a floor of the enclosure; and
a platform slidably connected to the plurality of lateral rails and
having the plurality of longitudinal rails mounted thereon so that
the DDU slidably connects to the longitudinal rails when positioned
thereon thereby defining a DDU-mounted platform, the DDU being
movable in the longitudinal direction along the longitudinal rails
to longitudinally position the DDU within the enclosure, and the
DDU-mounted platform movable in the lateral direction along the
lateral rails to remove the DDU-mounted platform from the
enclosure.
2. The DDU positioner assembly of claim 1, further comprising a
plurality of lateral guide rollers slidably connecting the platform
to a respective lateral rail of the plurality of lateral rails and
a plurality of longitudinal guide rollers to slidably connect the
DDU to a respective longitudinal rail of the plurality of
longitudinal rails.
3. The DDU positioner assembly of claim 2, wherein the plurality of
longitudinal guide rollers is positioned longitudinally between the
plurality of lateral guide rollers.
4. The DDU positioner assembly of claim 3, wherein the platform is
mounted to overlie the plurality of lateral guide rollers, and
wherein the plurality of longitudinal rails is mounted to overlie
the platform.
5. The DDU positioner assembly of claim 4, wherein the plurality of
longitudinal guide rollers is configured to connect to the gearbox
when positioned adjacent thereto.
6. The DDU positioner assembly of claim 4, further comprising a
plurality of locking mechanisms for locking the platform in a fixed
position on the plurality of lateral rails and the plurality of
longitudinal rails.
7. The DDU positioner assembly of claim 2, wherein the platform is
configured to connect to a support of the gearbox when positioned
adjacent thereto, and the turbine engine is mounted to the gearbox
and extends in the longitudinal direction from the gearbox.
Description
BACKGROUND OF THE DISCLOSURE
This disclosure relates to embodiments of systems and methods for
the removal and/or positioning of a direct drive unit housed in an
enclosure, such as a direct drive turbine (DDT) when connected to a
gearbox for driving a driveshaft, which, in turn, may be connected
to a pump such as for use in a hydraulic fracturing system.
Traditional fracturing pumping fleets have had fuel supplied from a
single fuel source. In such units, when a unit runs low on fuel
(for example diesel), that unit is shutdown while another stand by
unit is brought in, refueled, and then put into service. Some
inefficiencies included in this process are that the unit once low
on primary fuel must be stopped, refueled while another unit is
simultaneously being introduced into its place to make up for the
loss of the pumping power that the unit provides. This may affect
the pumping performance during a section as well as requiring human
intervention to perform the refueling, lining up suction and
discharge valves. This may require multiple personnel to relay back
the information so the process is performed in the correct series
of steps. Using a single fuel source also limits the ability for
the fracturing fleet to make it continuously through a section when
low on fuel which results in delays in pumping completion.
In addition, in cases where the unit needs to be taken offline for
maintenance or replacement, significant disassembly is required to
remove the unit from its enclosure and to install a replacement
unit, potentially resulting in excessive downtime. In some cases,
the entire trailer and enclosure need to be removed from the site
so a new, fully equipped trailer may be moved into place.
Accordingly, it may be seen that a need exists for more efficient
ways of accessing the drive units for maintenance purposes and/or
replacement with minimum disruption to the system operations and
the surrounding equipment. The present disclosure addresses these
and other related and unrelated problems in the art.
SUMMARY OF THE DISCLOSURE
According to one embodiment of the disclosure, a method of removing
a direct drive unit (DDU) housed in an enclosure. The DDU includes
a gearbox and a turbine engine connected to the gearbox for driving
a driveshaft connected to a pump for use in high-pressure,
high-power hydraulic fracturing operations. The method may include
accessing the enclosure. The enclosure contains air inlet ducting
connected to the turbine engine and air exhaust ducting connected
to the turbine engine. The method may further include disconnecting
the turbine engine from the air inlet ducting, disconnecting the
turbine engine from at least one fuel line, disconnecting the
gearbox from the driveshaft, disconnecting the turbine engine from
an at least one exhaust flange connected to the air exhaust
ducting, and operating a DDU positioner assembly to position the
DDU for withdrawal from the enclosure, and removing the DDU from
the enclosure.
According to another embodiment of the disclosure, a direct drive
unit (DDU) positioner assembly is disclosed for positioning a DDU
housed in an enclosure for removal from the enclosure. The DDU
includes a gearbox and a turbine engine connected to the gearbox
for driving a driveshaft connected to a pump for use in
high-pressure, high-power hydraulic fracturing operations. The DDU
positioner assembly may include a plurality of longitudinal rails
extending in a longitudinal direction along the central axis of the
DDU and a plurality of lateral rails extending in a lateral
direction transverse to the longitudinal direction. The DDU
positioner assembly may further include a platform slidably
connected to the plurality of lateral rails. The plurality of
longitudinal rails may be mounted on the platform and the DDU may
be slidably connected to the longitudinal rails. The DDU may be
movable in the longitudinal direction along the longitudinal rails
and the platform may be movable in the lateral direction along the
lateral rails.
According to yet another embodiment of the disclosure, a direct
drive unit (DDU) positioner assembly is disclosed for positioning a
DDU housed in an enclosure for removal from the enclosure. The DDU
includes a gearbox and a turbine engine connected to the gearbox
for driving a driveshaft connected to a pump for use in
high-pressure, high-power, hydraulic fracturing operations. The DDU
positioner assembly may include a platform connected to a support
of the gearbox and mounted on an enclosure base of the enclosure.
The enclosure base may have a plurality of lubrication grooves for
facilitating sliding movement of the platform relative to the
enclosure base. The DDU positioner assembly may include a
lubricator to convey lubricant to the lubrication grooves. The
platform may be fixedly attached to the enclosure base by one or
more fasteners during operation of the DDU and in slidable
engagement with the enclosure base upon removal of the one or more
fasteners.
Those skilled in the art will appreciate the benefits of various
additional embodiments reading the following detailed description
of the embodiments with reference to the below-listed drawing
figures. It is within the scope of the present disclosure that the
above-discussed aspects be provided both individually and in
various combinations.
BRIEF DESCRIPTION OF THE DRAWINGS
According to common practice, the various features of the drawings
discussed below are not necessarily drawn to scale. Dimensions of
various features and elements in the drawings may be expanded or
reduced to more clearly illustrate the embodiments of the
disclosure.
FIG. 1A is a schematic diagram of a pumping unit according to an
embodiment of the disclosure.
FIG. 1B is a schematic diagram of a layout of a fluid pumping
system according to an embodiment of the disclosure.
FIG. 2 is a perspective view of an enclosure for housing a direct
drive unit (DDU) according to an embodiment of the disclosure.
FIG. 3 is a top plan view of the enclosure housing the DDU
according to an embodiment of the disclosure.
FIG. 4 is a side elevation view of the DDU mounted on a DDU
positioner assembly according to a first embodiment of the
disclosure.
FIG. 5 is an end elevation view of the DDU of FIG. 4 according to a
first embodiment of the disclosure.
FIG. 6A is a perspective view of the DDU of FIG. 4 in a first
position according to a first embodiment of the disclosure.
FIG. 6B is a perspective view of the DDU of FIG. 6A moved to a
second position according to a first embodiment of the
disclosure.
FIG. 6C is a perspective view of the DDU of FIG. 6B moved to a
third position according to a first embodiment of the
disclosure.
FIG. 7 is a side elevation view of the DDU mounted on a DDU
positioner assembly according to a second embodiment of the
disclosure.
FIG. 8A is a perspective view of the DDU of FIG. 7 in a first
position according to a second embodiment of the disclosure.
FIG. 8B is a perspective view of the DDU of FIG. 8A moved to a
second position according to a second embodiment of the
disclosure.
FIG. 8C is a perspective view of the DDU of FIG. 8B moved to a
third position according to a second embodiment of the
disclosure.
FIG. 9 is an enlarged detail of a portion of the DDU positioner
assembly according to a second embodiment of the disclosure.
FIG. 10 is a detail of a portion of the DDU positioner assembly
according to a second embodiment.
FIG. 11 is a side elevation view of the DDU mounted on a DDU
positioner assembly according to a third embodiment of the
disclosure.
FIG. 12A is a perspective view of the DDU of FIG. 11 in a first
position according to a third embodiment of the disclosure.
FIG. 12B is a perspective view of the DDU of FIG. 12A moved to a
second position according to a third embodiment of the
disclosure.
FIG. 12C is a perspective view of the DDU of FIG. 12B moved to a
third position according to a third embodiment of the
disclosure.
Corresponding parts are designated by corresponding reference
numbers throughout the drawings.
DETAILED DESCRIPTION
Generally, this disclosure is directed to a direct drive unit (DDU)
positioner assembly, positioning system, removal system, and/or
associated mechanisms that will allow a DDU including a gearbox and
a turbine engine connected to the gearbox to be detached from
surrounding equipment and removed through the side of an enclosure
housing the direct drive unit. The system will allow for
inspections, maintenance, or even a complete exchange of the direct
drive unit with another if necessary.
FIG. 1A illustrates a schematic view of a pumping unit 11 for use
in a high-pressure, high power, fluid pumping system 13 (FIG. 1B)
for use in hydraulic fracturing operations according to one
embodiment of the disclosure. FIG. 1B shows a typical pad layout of
the pumping units 11 (indicated as FP1, FP2, FP3, FP4, FP5, FP6,
FP7, FP8) with the pumping units all operatively connected to a
manifold M that is operatively connected to a wellhead W. By way of
an example, the system 13 is a hydraulic fracturing application
that may be sized to achieve a maximum rated horsepower of 24,000
HP for the pumping system 13, including a quantity of eight (8)
3000 horsepower (HP) pumping units 11 that may be used in one
embodiment of the disclosure. It will be understood that the fluid
pumping system 13 may include associated service equipment such as
hoses, connections, and assemblies, among other devices and tools.
As shown in FIG. 1, each of the pumping units 11 are mounted on a
trailer 15 for transport and positioning at the jobsite. Each
pumping unit 11 includes an enclosure 21 that houses a direct drive
unit (DDU) 23 including a gas turbine engine 25 operatively
connected to a gearbox 27. The pumping unit 11 has a driveshaft 31
operatively connected to the gearbox 27. The pumping unit 11
includes a high-pressure, high-power, reciprocating positive
displacement pump 33 that is operatively connected to the DDU 23
via the driveshaft 31. In one embodiment, the pumping unit 11 is
mounted on the trailer 15 adjacent the DDU 23. The trailer 15
includes other associated components such as a turbine exhaust duct
35 operatively connected to the gas turbine engine 25, air intake
duct 37 operatively connected to the gas turbine, and other
associated equipment hoses, connections, etc. to facilitate
operation of the fluid pumping unit 11.
In the illustrated embodiment, the gas turbine engine 25 is a
Vericor Model TF50F bi-fuel turbine; however, the direct drive unit
23 may include other gas turbines or suitable drive units, systems,
and/or mechanisms suitable for use as a hydraulic fracturing pump
drive without departing from the disclosure. The gas turbine engine
25 is cantilever mounted to the gearbox 27 with the gearbox
supported by the floor 41 of the enclosure 21. The gearbox 27 may
be a reduction helical gearbox that has a constant running power
rating of 5500 SHP and intermittent power output of 5850 SHP, or
other suitable gearbox. It should also be noted that, while the
disclosure primarily describes the systems and mechanisms for use
with direct drive units 23 to operate fracturing pumping units 33,
the disclosed systems and mechanisms may also be directed to other
equipment within the well stimulation industry such as, for
example, blenders, cementing units, power generators and related
equipment, without departing from the scope of the disclosure.
FIG. 2 illustrates the enclosure 21 that houses the direct drive
unit 23 in an interior space 46 of the enclosure. In one
embodiment, the enclosure has access doors 45 for removal of the
DDU 23 from the enclosure and/or other components within the
enclosure. The enclosure 21 provides sound attenuation of the DDU
23 during operation.
As shown in FIG. 3, the direct drive unit 23 and the enclosure 21
has a longitudinal axis L1 and a lateral axis L2 transverse to the
longitudinal axis. FIG. 3 illustrates a top view of the enclosure
21 with the DDU 23 shown attached to the driveshaft 31 that extends
through an opening 48 in a first longitudinal end 47 of the
enclosure. An air exhaust assembly 35 extends through a second
longitudinal end 49 of the enclosure. The DDU 23 has a central axis
CL extending in the longitudinal direction L1 that extends through
the centerline of the unit and is aligned with the centerline of
the driveshaft 31. The gearbox 27 includes an outlet flange 50 that
is connected to the driveshaft 31. The gas turbine engine 25 has
two air inlet ports 51, 53 on a respective lateral side of the
central axis CL and an exhaust duct flange 54 that connects the gas
turbine engine to the air exhaust assembly 35 at the longitudinal
end 49 of the enclosure 21. In one embodiment, the access doors 45
are mounted on a first lateral side 55 of the enclosure 21, but the
enclosure may have additional access doors on a second lateral side
57 of the enclosure, or the access doors may be positioned only on
the second lateral side without departing from the scope of this
disclosure. The gas turbine engine 25 may include polymer expansion
joints 61, 63 connected to air inlet ports 51, 53, to facilitate
the removal of the gas turbine engine from the enclosure 21. The
gas turbine engine 25 may include various fuel lines, communication
lines, hydraulic and pneumatic connections, and other connections
or accessories needed for operation of the gas turbine engine
without departing from the disclosure. Such connections may utilize
quick disconnect fittings and check valves to facilitate
disconnection of the gas turbine engine 25 during removal of the
DDU 23 from the enclosure 21. Further, such connections such as
fuel lines and hydraulic lines may run to a single bulkhead (not
shown) within or near the enclosure to allow for quick
disconnection by locating these connections in a common
location.
FIG. 4 is a side elevation view of the DDU 23 as viewed from the
lateral side 55 of the enclosure 21, with the DDU being mounted on
a DDU positioner assembly or DDU positioning system 101 (FIGS.
4-6C) for positioning the DDU for withdrawal or removal from the
enclosure through the access doors 45. In one embodiment, the DDU
positioner assembly 101 comprises a platform 103 slidably mounted
to overlie two lateral rails 105, 107 mounted to overlie the floor
41 of the enclosure 21 and extending laterally across the enclosure
generally between the lateral sides 55, 57. The DDU positioner
assembly 101 comprises two longitudinal rails 109, 111 mounted to
overlie the platform 103 and extending in the longitudinal
direction L1. The DDU 23 is slidably mounted on the longitudinal
rails 109, 111 for positioning the DDU in the longitudinal
direction L1. In one embodiment, the DDU positioner assembly 101
includes lateral guide rollers 115, 117 mounted on a respective
lateral rail 105, 107, and longitudinal guide rollers 121, 123
mounted on a respective longitudinal rail 109, 111. The platform
103 is connected to the lateral guide rollers 115, 117 to allow
slidable movement and positioning of the DDU 23 mounted on the
platform in the lateral direction L2 via the lateral rails 105,
107. The longitudinal guide rollers 121, 123 are connected to a
mounting base 127 of the gearbox 27 to allow slidable movement and
positioning of the DDU 23 in the longitudinal direction L1 via the
longitudinal rails 109, 111. In one embodiment, the DDU positioner
assembly 101 includes four lateral guide rollers 115, 117 and four
longitudinal guide rollers 121, 123, but more or less than eight
guide rollers may be provided without departing from the scope of
the disclosure. Further, more or less than two longitudinal rails
109, 111, and more or less than two lateral rails 105, 107 may be
provided without departing from the scope of the disclosure. In one
embodiment, the guide rollers 115, 117, 121, 123 may be a caged
ball type linear motion (LM) Guide, model number SPS20LR available
from THK America Inc., or any similar make or model number without
departing from the scope of the disclosure. The DDU positioner
assembly 101 may be equipped with locking mechanisms 128 mounted on
a respective guide roller 115, 117, 121, 123. The locking
mechanisms 128 may be spring loaded and will default to the locked
position to allow the DDU 23 to be secured in the operating
position. The locking mechanism 128 may be otherwise located on the
positioning system 101 without departing from the disclosure.
Exemplary loading calculations for sizing the guide rails 105, 107,
109, 111 are shown below and are based on the Vericor TF50F turbine
parameters as follows: approximate turbine weight, 1475 lbs.;
approximate fuel system weight, 85 lbs.; approximate gearbox
weight, 4000 lbs.; for a total approximate weight of 5559 lbs.
Various other parameters may be applicable based on the make,
model, and size of the gas turbine engine 25.
Because of the arrangement the direct drive unit 23 including the
gas turbine engine 25 cantilever mounted onto the gearbox 27 and
extending in the longitudinal direction L1 from the gearbox, there
is added load put onto the rear lateral guide rollers 115 and the
rear longitudinal guide rollers 121, 123 (the guide rollers mounted
closest to the gas turbine engine). Accordingly, an increased load
rating may be applied to the rear guide rollers 115, 121, 123 if
required. The calculation of the cantilever load and the reaction
forces may be calculated with the formulas shown below, which may
also be used for further design and implementation of the disclosed
removal mechanisms.
Maximum Reaction at the fixed end may be expressed as:
R.sub.A=qL.
where: R.sub.A=reaction force in A (N, lb), q=uniform distributed
load (N/m, N/mm, lb/in), and
L=length of cantilever beam (m, mm, in).
Maximum Moment at the fixed end may be expressed as M.sub.A=-q
L.sup.2/2
Maximum Deflection at the end may be expressed as .delta..sub.B=q
L.sup.4/(8 E I).
where: .delta..sub.B=maximum deflection in B (m, mm, in).
In one embodiment, the longitudinal guide rollers 121, 123
connected to the support structure 127 of the gearbox 27 are
positioned between each pair of the lateral guide rollers 115, 117
to ensure equal weight distribution over the platform 103 and to
avoid cantilever loading the platform. Different configurations of
platforms, sliders, rails and mounts are contemplated and
considered within the scope of the disclosure. The configurations
of the DDU positioner assembly 101 may vary to suit a particular
DDU 23 with various alternative combinations of makes, model, and
sizes of the gas turbine engine 25 and the gearbox 27.
In one embodiment, the guide rails 105, 107, 109, 111 are made from
a steel composition that has been mill finished and shot blasted to
protect the rail from the high heat environment within the turbine
enclosure 21 and ensure strength retention under the exposed
temperatures. In one embodiment, the platform 103 is constructed
out of a composite material; however, other materials are
contemplated and considered within the scope of the disclosure,
such as but not limited to, steel or stainless steel. The guide
rails 105, 107, 109, 111, platform 103, and/or other components of
the DDU positioner assembly 101 may be made of various other
suitable materials without departing from the scope of the
disclosure.
FIGS. 6A-6B illustrate an exemplary method of removing the direct
drive unit 23 from the enclosure 21 utilizing the DDU positioner
assembly 101. FIG. 6A shows the DDU 23 in a first/operating
position for operation with the pump 33 of the pumping unit 11. The
method includes accessing the enclosure 21 and disconnecting the
gas turbine engine 25 from the air inlet ducting 37. The flanges
51, 53 may be disconnected from the air inlet ducting 37 and the
expansion joints 61, 63 flexed to allow separation of the DDU 23
from the air inlet ducting. The gas turbine engine 25 may be
disconnected from the air exhaust ducting 35 by disconnecting the
exhaust duct flange 54 from the air exhaust ducting. Corresponding
hoses, piping, wiring, and cabling including fuel lines, electrical
lines, hydraulic lines, control lines or any other connection that
is needed for operation of the gas turbine engine 25 may also be
disconnected so that the gas turbine engine is free to move without
damaging any of the operational connections needed for operation of
the gas turbine engine. For example, the air bleed off valve
ducting may be removed from the turbine engine 25 and secured at a
location free of interference with movement of the turbine engine.
Alternatively, some hoses, piping, wiring, etc. may include enough
slack or flexibility so that the DDU 23 may be initially moved
before complete disconnection of the connections from the gas
turbine engine 25 are required for removal of the DDU from the
enclosure 21. The gearbox 27 may be disconnected from the
driveshaft 31 by disconnecting the outlet flange 50 from the
driveshaft. In one embodiment, the driveshaft 31 may be a slip-fit
driveshaft allowing the driveshaft to contract to facilitate
disconnection from the DDU 23. In one embodiment, the driveshaft 31
may be a 390. Series, GWB Model 390.80 driveshaft available Dana
Corporation, or other suitable driveshaft. The gearbox 27 may be
disconnected from any other connections needed for operation of the
DDU 23 to obtain freedom of movement of the gearbox without
damaging any of the operating connections.
Once the gas turbine engine 25 is disconnected from the respective
connections and the gearbox 27 is disconnected from the driveshaft
31, the DDU positioner assembly 101 is operated to position the
direct drive unit 23 for withdrawal from the enclosure 21. As shown
in FIG. 6B, the DDU 23 is positioned in a second position where the
DDU is first moved in the longitudinal direction L1 in the
direction of arrow A1 by sliding the DDU along the longitudinal
rails 109, 111. In one embodiment, prior to initial movement of the
DDU 23 in the longitudinal direction L1, the longitudinal locks 128
associated with the longitudinal guide rollers 121, 123 must be
released to allow the movement of the DDU in the longitudinal
direction. After the movement of the DDU 23 in the longitudinal
direction L1 to the second position, the longitudinal locks 128 may
be reengaged to lock the longitudinal guide rollers 121, 123 and
prevent further or additional unwanted movement of the DDU 23 along
the longitudinal rails 109, 111, and the lateral locks 128
associated with the lateral guide rollers 115, 117 may be
disengaged to allow lateral movement of the DDU 23. Next, the
platform 103 may be moved to a third position by moving in the
lateral direction L2 in the direction of arrow A2 (FIG. 6C) by
sliding movement of the lateral guide rollers 115, 117 along the
lateral guide rails 105, 107. The DDU 23 is mounted to the platform
103 and moves with the platform in the lateral direction L2 to the
third position of FIG. 6C. As shown in FIGS. 3 and 5, the lateral
guide rails 105, 107 may extend to the access doors 45 in either
side 55, 57 of the enclosure 21. In some embodiments, lateral guide
rail extensions 107' (FIG. 5) may be used to extend outside of the
enclosure 21 to allow the platform 103 and DDU 23 to be slid out of
the enclosure onto an adjacent supporting structure or vehicle
(e.g., maintenance inspection platform or other suitable
structure), or the platform 103 and DDU 23 may be accessed through
the access doors 45 of the enclosure 21 by a lifting mechanism
(e.g., a forklift, crane, or other suitable lifting mechanism) to
fully remove the DDU from the enclosure. The various method steps
described herein for the method of positioning or removing the DDU
23 may be otherwise performed in an alternative order or
simultaneously, or more or less steps may be used without departing
from the scope of the disclosure.
FIGS. 7-10 illustrates a second embodiment of a DDU positioner
assembly or system 201 for positioning the direct drive unit 23
housed in the enclosure 21. In the illustrated embodiment, the DDU
23 includes a gas turbine engine 25 and a gearbox 27 identical to
the first embodiment of the disclosure, but the DDU positioner
assembly 201 may be used to position a DDU that is alternatively
configured without departing from the disclosure. As such, like or
similar reference numbers will be used to describe identical or
similar features between the two embodiments.
In one embodiment, the DDU positioner assembly 201 includes a
platform 203 that supports the gearbox 27 and has a top surface
205, a bottom surface 207, two sides 208, and two ends 210. The
gearbox 27 is fixedly mounted to the top surface 205 of the
platform 203. The platform 203 is slidably mounted on the base 41
of the enclosure 21 with the bottom surface 207 of the platform
being in slidable engagement with the floor of the enclosure. In a
first or operating position (FIGS. 7 and 8A) of the direct drive
unit 23, the platform 203 is fixedly attached to the base 41 by a
plurality of fasteners 211. Upon removal of the fasteners 211, the
platform 203 is capable of slidable movement with respect to the
base 41. The platform 203 is connected to the support structure 127
of the gearbox 27 so that the drive unit 23 moves with the
platform. In one embodiment, the platform 203 has two lifting
openings 215, 217 extending between respective sides 208 of the
platform. As shown in FIG. 7, the lifting opening 215 towards the
front of the gearbox 27 (closest to the drive shaft flange 50) is
spaced a first distance D1 from a centerline CT of the gearbox and
the lifting opening 217 towards the rear of the gearbox (closest to
the gas turbine engine 25) is spaced a second distance from the
centerline CT of the gearbox, with the distance D2 being greater
than the distance D2. The rear lifting opening 217 is farther from
the centerline CT of the gearbox 27 because of the cantilever
mounted gas turbine engine 25 that shifts the center of gravity of
the DDU 23 from the centerline CT of the gearbox in the
longitudinal direction toward the gas turbine engine. The platform
203 may be otherwise configured and/or arranged without departing
from the scope of the disclosure.
In one embodiment, the DDU positioner assembly 201 includes a
lubricator or lubrication system 221 (FIG. 9) to convey lubricant
(e.g., grease or other suitable lubricant) from a lubricant
reservoir 244 to a location between the bottom surface 207 of the
platform 201 and the base 41 of the enclosure. The DDU positioner
assembly 201 includes a lubrication portion 225 (FIG. 10) of the
base 41 below the platform 203. As shown in FIG. 10, the portion
225 of the base 41 includes a plurality of lubrication grooves 227.
The lubrication grooves 227 are in fluid communication with the
lubricator 221 so that the lubricator provides lubricant to the
grooves to facilitate sliding engagement between the platform 203
and the portion 225 of the base 41. The lubricator 221 includes a
source of lubricant 244, tubing 243, and other required components
(e.g., pump, controls, etc.) for delivering the lubricant to the
lubrication portion 225 at a sufficiently high pressure for
lubricant to fill the grooves 227 of the lubrication portion 225.
In one embodiment, the lubricator 221 may be an automatic
lubricator such as a model TLMP lubricator available from SKF
Corporation, or the lubricator may be any other suitable lubricator
including other automatic lubricators or manual lubricators without
departing from the scope of the disclosure. In one embodiment, the
lubrication portion 225 of the base 41 is an integral portion with
the base or the floor of the enclosure 21, but the lubrication
portion 225 may be a separate pad or component that is mounted
between the base and the platform without departing from the
disclosure. The lubricator 221 may be mounted inside the enclosure
21 or at least partially outside the enclosure without departing
from the scope of the disclosure.
In one embodiment, the DDU positioner assembly 201 includes drive
fasteners 241 mounted at one end 210 of the platform 203. In the
illustrated embodiment, the drive fasteners 241 include a bracket
245 mounted to the floor 41 of the enclosure 21 and an impact screw
247 operatively connected to the bracket and the platform 203. The
drive fasteners 241 may have other components and be otherwise
arranged without departing from the disclosure. Further, more or
less than two drive fasteners 241 may be provided without departing
from the disclosure.
FIGS. 8A-9 illustrate an exemplary method of removing the DDU 23
from the enclosure 21 utilizing the DDU positioner assembly 201 of
the second embodiment. The method is similar to the method of the
first embodiment, in that the gas turbine engine 25 is disconnected
from the air inlet ducting 37, the air exhaust ducting 35, and from
other corresponding connections and components in a similar manner
as discussed above for the first embodiment so that the gas turbine
engine is free to move without damaging any of the operational
connections and components needed for operation of the gas turbine
engine. Further, the gearbox 27 is disconnected from the driveshaft
31 in a similar manner as the first embodiment, so that the DDU 23
has clearance for movement in the longitudinal direction L1 without
interference with the driveshaft.
FIG. 8A shows the direct drive unit 23 in the first/operating
position. Once the gas turbine engine 25 is disconnected from the
respective components and connections and the gearbox 27 is
disconnected from the driveshaft 31 and any other connections, the
DDU positioner assembly 201 is operated to position the DDU 23 for
withdrawal from the enclosure 21. First, the fasteners 211 fixedly
attaching the platform 203 to the base 41 are removed. The
lubricator 221 is operated to convey lubricant to the lubrication
grooves 227 of the lubrication portion 225 of the base 41. After a
sufficient amount of lubrication is located between the platform
203 and the lubrication portion 225 of the base 41, the drive
fasteners 241 may be operated to move the platform 203 in the
longitudinal direction L1 to a second position (FIG. 8B). As the
impact screws 247 of the drive fasteners 241 are turned, the
platform 203 is slid in the longitudinal direction L1 in the
direction of arrow A3 (FIG. 8B). The lubricant provided in the
lubrication grooves 227 and between the lubrication portion 225 and
the bottom surface 207 of the platform reduces the sliding friction
and allows the rotation of the impact screws 247 in the bracket 245
to advance the platform in the direction of arrow A3. The platform
203 is moved in the direction of arrow A3 a sufficient amount to
allow access to the lifting openings 215, 217 by a lifting
mechanism (e.g., forklift) 261 (FIG. 8C). The lifting mechanism 261
may include a forklift or other lifting mechanism that may access
the interior 46 of the enclosure through the enclosure access doors
45. The lifting mechanism 261 is inserted into the lifting openings
215, 217 of the platform 203, and the DDU 23 is lifted and/or slid
in the direction of arrow A4. The lifting mechanism 261 may move
the DDU 23 to the third position (FIG. 8C), or transfer the DDU
onto an adjacent supporting structure or vehicle (e.g., maintenance
inspection platform or other suitable structure), or completely
remove the platform 203 and DDU 23 from the enclosure. The various
method steps described herein for the method of positioning or
removing the DDU 23 by operating the DDU positioner assembly 201
may be otherwise performed in an alternative order or
simultaneously, or more or less steps may be used without departing
from the scope of the disclosure.
FIGS. 11-12C illustrate a third embodiment of a DDU positioner
assembly or system 301 for positioning the direct drive unit 23
housed in the enclosure 21. In the illustrated embodiment, the DDU
23 includes a gas turbine engine 25 and a gearbox 27 identical to
the first and second embodiments of the disclosure, but the DDU
positioner assembly 301 may be used to position a DDU that is
alternatively configured without departing from the disclosure as
will be understood by those skilled in the art. The DDU positioner
assembly 301 is generally similar to the DDU positioner assembly
201 of the second embodiment, except the drive fasteners 241 have
been removed and an actuator 341 is added to the DDU positioner
assembly of the third embodiment. As such, like or similar
reference numbers will be used to describe identical or similar
features between the second and third embodiments.
As shown in FIG. 11, the DDU positioner assembly 301 includes the
actuator 341 that has a first end 345 connected to the base 41 of
the enclosure 21 and a second end 347 connected to the end 210 of
the platform 203. In one embodiment, the actuator 341 is a
hydraulic cylinder that has a piston rod 351 that is extendible
from a cylinder body 349 upon operation of the actuator. The
actuator 341 may be controlled by a manual control valve or the
actuator may be configured for remote operation by connection to
corresponding automated control valves. In the illustrated
embodiment, one actuator 341 is shown, but the DDU positioner
assembly 301 may include more than one actuator without departing
from the scope of the disclosure. Further, the actuator 341 may be
otherwise located for attachment to the platform 203 without
departing from the scope of the disclosure.
FIGS. 12A-12C illustrate an exemplary method of removing the DDU 23
from the enclosure 21 utilizing the DDU positioner assembly 301 of
the second embodiment. The method is similar to the method of the
utilizing the DDU positioner assembly 201 of the second embodiment,
in that the gas turbine engine 25 is disconnected from the air
inlet ducting 37, the air exhaust ducting 35, and from other
corresponding connections and components in a similar manner as
discussed above for the first embodiment so that the gas turbine
engine is free to move without damaging any of the operational
connections and components needed for operation of the gas turbine
engine. Further, the gearbox 27 is disconnected from the driveshaft
31 in a similar manner as the first embodiment, so that the DDU 23
has clearance for movement in the longitudinal direction L1 without
interference with the driveshaft. Also, the DDU positioner assembly
301 of the third embodiment includes the lubricator 221 (FIG. 9)
for providing lubrication to lubrication grooves 227 of the
lubrication portion 225 of the base 41 to facilitate sliding of the
platform 203 in the longitudinal direction L1, so that the DDU
positioner assembly of the third embodiment operates in a similar
manner as the DDU positioner assembly 201 of the second
embodiment.
FIG. 12A shows the direct drive unit 23 in the first/operating
position. Once the gas turbine engine 25 is disconnected from the
respective components and connections, and the gearbox 27 is
disconnected from the driveshaft 31 and any other connections, the
DDU positioner assembly 301 is operated to position the DDU 23 for
withdrawal from the enclosure 21. First, the fasteners 211 fixedly
attaching the platform 203 to the base 41 are removed. The
lubricator 221 is operated to convey lubricant to the lubrication
grooves 227 of the lubrication portion 225 of the base 41. After a
sufficient amount of lubrication is located between the platform
203 and the lubrication portion 225 of the base 41, the actuator
341 may be operated to move the platform 203 in the longitudinal
direction L1 to a second position (FIG. 12B). The extension of the
piston rod 351 of the actuator 341 exerts a force on the platform
203 to slide the platform in the longitudinal direction L1 in the
direction of arrow A3 (FIG. 12B). The lubricant provided in the
lubrication grooves 227 and between the lubrication portion 225 and
the bottom surface 207 of the platform reduces the sliding friction
and allows the actuator 341 to advance the platform in the
direction of arrow A3. As with the previous embodiment, the
platform 203 is moved in the direction of arrow A3 a sufficient
distance to allow access to the lifting openings 215, 217 by a
lifting mechanism (e.g., forklift) 261 (FIG. 8C). The lifting
mechanism 261 may include a forklift or other lifting mechanism
that may access the interior 46 of the enclosure through the
enclosure access doors 45. The lifting mechanism 261 is inserted
into the lifting openings 215, 217 of the platform 203, and the DDU
23 is lifted and/or slid in the direction of arrow A4. Prior to
moving the platform 203 in the direction of arrow A4, the actuator
341 may be disconnected from the platform (FIG. 12C) with the first
end 347 of the actuator being separated from the platform and the
second end 345 of the actuator remaining attached to the floor 41
of the enclosure. Alternatively, the second end 345 of the actuator
341 may be disconnected from the floor 41 of the enclosure and the
first end 341 of the actuator may remain attached to the platform
203, or both ends of the actuator may be disconnected and the
actuator removed without departing from the enclosure.
The lifting mechanism 261 may move the DDU 23 to the third position
(FIG. 12C), or transfer the DDU onto an adjacent supporting
structure or vehicle (e.g., maintenance inspection platform or
other suitable structure), or completely remove the platform 203
and DDU 23 from the enclosure. The various method steps described
herein for the method of positioning or removing the DDU 23 by
operating the DDU positioner assembly 301 may be otherwise
performed in an alternative order or simultaneously, or more or
less steps may be used without departing from the scope of the
disclosure.
Having now described some illustrative embodiments of the
disclosure, it should be apparent to those skilled in the art that
the foregoing is merely illustrative and not limiting, having been
presented by way of example only. Numerous modifications and other
embodiments are within the scope of one of ordinary skill in the
art and are contemplated as falling within the scope of the
disclosure. In particular, although many of the examples presented
herein involve specific combinations of method acts or system
elements, it should be understood that those acts and those
elements may be combined in other ways to accomplish the same
objectives. Those skilled in the art should appreciate that the
parameters and configurations described herein are exemplary and
that actual parameters and/or configurations will depend on the
specific application in which the systems and techniques are used.
Those skilled in the art should also recognize or be able to
ascertain, using no more than routine experimentation, equivalents
to the specific embodiments of the disclosure. It is, therefore, to
be understood that the embodiments described herein are presented
by way of example only and that, within the scope of any appended
claims and equivalents thereto; the embodiments of the disclosure
may be practiced other than as specifically described.
Furthermore, the scope of the present disclosure shall be construed
to cover various modifications, combinations, additions,
alterations, etc., above and to the above-described embodiments,
which shall be considered to be within the scope of this
disclosure. Accordingly, various features and characteristics as
discussed herein may be selectively interchanged and applied to
other illustrated and non-illustrated embodiment, and numerous
variations, modifications, and additions further may be made
thereto without departing from the spirit and scope of the present
disclosure as set forth in the appended claims.
* * * * *